///80 Series Monster Bus

[Sabbath']

Not yet strike, will be done sometime before 2016.



Started mocking up the rough location the intercooler will sit today. Soewhere abouts here should do nicely.

 

[dingeldei]

sweet rig, wouldnt mind getting one myself

 

[Sabbath']

Finally got around to doing some more work on mocking up the intercooler for install.

I was at first having issues with the height of the intercooler to the bonnet. I removed the lining and that gave me enough clearance to sit it up directly ontop of the rocker cover.

But that in itself raises a couple of issues.

First being mounting, it sits in a way that it only has clearance when it sits flush onto the rocker cover. So apart from laying down a layer of rubber between it and the rocker cover it's going to be short lived.

The other being the angle of th pipework.

Im getting a 45 Degree reducer but that's going to require more space to push it over towards the exhaust manifold.

So as i posted a couple of posts ago, probably going to hang it off the hot side of the motor and heat shield it. The radiant heat shouldnt be too much of an effect im hoping as there will be a significant air gap and a double layer of heat shielding.

 

[Sabbath']

Started knocking up some brackets for the intercooler, if i mount it over and back a bit more i can keep the airbox > turbo pipe the same as it is now and then just have to play with the hot side.

Decided that i would make brackets with alot of adjustability in them because it's nigh on impossible to place the intercooler strategically while perched on the bullbar.

This was one of the routes i was playing with for the cold side. As you can see, for a big 4wd, there's not much room in the bay with the extra battery shoved in there.

Mounting points on the head

Brackets i bent up

And how they'll attach

Aaaaaand...Because Turbo!

 

[hi_ryder]

v-tec just kicked in yo....

 

[HamaTime™]

ooooooooooh.

Very nice. I like.

 

[Sabbath']

Havent done much on the intercooler side of things as i've loaned the Wagon to my mum because somebody re-arranged the back of her car so it's at the panel beaters.

Finally got the heat probe welded into the dump pipe for the Pyro gauge, temps are actually running really well considering it's an aftermarket turbo setup. And once i put the cooler on i should be able to squeeze some more boost out of it safely.

Also got my exhaust sorted, so it's now 3inches all the way from dump to tip, straight through. Mufflers all deleted.

Short clip.

https://www.dropbox.com/s/4t6u4ukordwowxj/20150507_121556.mp4?dl=0

 

[Ed]

3inch straight through, the only way on a diesel!

 

[Sabbath']

Pretty messy last couple of weeks in the land of cruiser...

Two weeks ago, had a bit of a family emergency which saw me push the cruiser way past what i should have. I ended up snapping the drivebelts for the waterpump/viscous fan. The belts were due for replacement but hadnt gotten around to it yada yada excuse excuse.

Due to circumstances i decided to keep going, as i was only approx 5 minutes from where we needed to get to.

Didnt end up making it that far. Driving along and the top tank on the radiator blew apart at the seam.

So that put a stop to the trip. And had to come back the next day and put it on the back of a towtruck. Which the towtruck didnt like very much. Had the cab of the towtruck lifted off the ground by about a foot trying to get the tray up. But made it and got it towed back home.

Removed the old radiator with the hopes of just getting it re-tanked and going on my way but it had ballooned out before it popped and contacted the viscous fan, causing damage to the core. So sourced a new one thanks to Hi_ryder's ebay skills


3 Core Brass/Copper. For less than $350 with overnight delivery. I did have the opportunity to pick up a 4 core (61mm thickness) but due to running a heat exchanger in the future i didnt want any more thickness than was necessary.

Removal of the old radiator meant that both batteries, both battery trays and the upper radiator support needed to be removed.

 

[Sabbath']

Bought a brand new set of belts and hoses as the alternator belts were toast, i had to undo the adjuster bolts and swing it up out of the way to accept the new belts. Decided to do this with the radiator out for more access.

Which is when i ran into a problem. Being that the adjuster bracket had actually snapped in two different places, meaning the alternator was flopping around under load.

So to get the bracket off meant removing the viscous fan and waterpump pulley. More work that i really didnt need/want.

Luckily i'm looking after Paradox's welder for him for a while so decided to try my hand at welding. Never welded anything before so took me a while to get it to a point that i was happy with. Lots of welding and grinding, and grinding and welding. In the end i think i got it pretty good. Enough to get the cruiser started atleast. I've got another one on order, because i dont trust a welded bracket and cant afford for this to happen somewhere remote.

For a radiator "guaranteed to fit 100%" i ran into issues getting the brackets on because the studs on the radiator are too far apart for the standard holes. Plus they've been painted over so getting the nuts started was a hassle. But the radiator is in now and that's where i left it for the night

Will most likely pull out the airbox tomorrow and do something about this mess before the battery goes back in. Also contemplating moving the compressor so i have more room for intercooler bracing.

And cause i had the camera out.

excuse the gangster lean...it's developed a flat sitting in the backyard for two weeks...cause enough **** hadnt gone wrong already